Multi-layered suspension package assembly

ABSTRACT

A packaging device can include a resilient member formed of two layers of different material, connected together such as by heat sealing. The layers can be made from different materials or the same materials having different thicknesses, modules of elasticity, melting index, or other different characteristics.

BACKGROUND OF THE INVENTIONS

1. Field of the Inventions

The present inventions are directed to a package assembly. Inparticular, the present inventions are directed to a suspension packageassembly that includes a stretchable retention member made from twolayers of material attached together.

2. Description of the Related Art

Protective packaging devices are often used to protect goods from shocksand impacts during shipping or transportation. For example, whentransporting articles that are relatively fragile, it is often desirableto cushion the article inside a box to protect the article from aphysical impact with the inner walls of the box that might be caused byshocks imparted to the box during loading, transit, and/or unloading.

In most cases, some additional structure is used to keep the articlefrom moving uncontrollably within the box. Such additional structuresinclude paper or plastic packing material, structured plastic foams,foam-filled cushions, and the like. Ideally, the article to be packagedis suspended within the box so as to be spaced from at least some of thewalls of the box, thus protecting the article from other foreign objectswhich may impact or compromise the outer walls of the box.

U.S. Pat. No. 6,675,973 discloses a number of inventions directed tosuspension packaging assemblies which incorporate frame members and oneor more retention members. For example, many of the embodiments of theU.S. Pat. No. 6,675,973 patent include the use of a retention memberformed of a resilient material. Additionally, some of the retentionmembers include pockets at opposite ends thereof.

In several of the embodiments disclosed in the U.S. Pat. No. 6,675,973patent, free ends of the frame members are inserted into the pockets ofthe retention member. The free ends of the frame member are then bent,pivoted, or folded to generate the desired tension in the retentionmember. Because the retention member is made from a resilient material,the retention member can stretch and thus provide a mechanism forsuspending an article to be packaged, for example, within a box.

SUMMARY OF THE INVENTIONS

An aspect of at least one of the embodiments disclosed herein includesthe realization that packaging devices that are designed to retain itemsto be packaged using a thin stretchable film can be further improved byforming the stretchable film member from two layers of materialconnected together. As such, the resulting resilient member can bemanufactured using high speed manufacturing processes, as well as otherbenefits.

For example, in some embodiments, the resilient member can be formedwith two layers of different material, heat sealed to one another. Insome cases, the two different materials can be different kinds ofmaterial, different thicknesses of the same material, different gradesof translucency (e.g., one layer being opaque and one layer beingtransparent), different modules of elasticity or other differentcharacteristics. When using heat sealing to attach the layers to oneanother, different materials having melt index values over a large rangeof such values can be used. For example, with regard to some materials,different layers made from different materials can be heat sealedtogether using high speed manufacturing equipment. Such high speed heatsealing is achieved more easily when the melt index of these materialsfalls approximately within the range of 7.0 to 10.0. However, othermaterials and other attachment techniques can also be used.

Thus, in accordance with an embodiment, a suspension packaging assemblycan comprise at least one frame member having a central portion, a firstend and a second end disposed opposite the first end relative to thecentral portion, a first foldable portion disposed at the first end anda second foldable portion disposed at the second end. Additionally, aresilient retention member can comprise a first layer having first andsecond longitudinal ends and first and second lateral edges and a secondlayer having first and second longitudinal ends and first and secondlateral edges, the first layer being heat sealed to the second layeralong the corresponding first and second lateral edges.

In accordance with another embodiment, a resilient member for providingdamage protection for packaged goods can comprise a first layer havingfirst and second longitudinal ends and first and second lateral edges. Asecond layer can include first and second longitudinal ends and firstand second lateral edges, where the first layer is heat sealed to thesecond layer along the corresponding first and second lateral edges.

All of these embodiments are intended to be within the scope of at leastone of the inventions disclosed herein. These and other embodiments ofthe inventions will become readily apparent to those skilled in the artfrom the following detailed description of the preferred embodimentshaving reference to the attached figures, the inventions not beinglimited to any particular preferred embodiment disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the inventions are described below withreference to the drawings of several embodiments of the present packageassemblies and kits which are intended to illustrate, but not to limit,the inventions. The drawings contain the following figures:

FIG. 1 is a plan view of a frame member having a central portion and twofoldable portions disposed at opposite ends relative to the centralportion.

FIG. 2 is a plan view of a resilient retention member formed of twolayers and having pockets disposed at opposite longitudinal ends.

FIG. 3 is a perspective view of the resilient retention memberillustrated in FIG. 2.

FIG. 4 is a schematic side elevational view of an assembly including theframe member of FIG. 1 and the resilient retention member of FIGS. 2-3connected together with an article packaged therewith.

FIG. 5 is a schematic side elevational view of the frame member inresilient retention member and article packaged therewith disposedinside a container.

FIG. 6 is a schematic view of a manufacturing device that can be used tomanufacture the resilient retention member illustrated in FIGS. 2-3.

FIG. 7 is a schematic illustration illustrating the function of anopening device that can be used at an opening station in the system ofFIG. 6.

FIG. 8 is a schematic plan view of a continuous strip of a plurality ofresilient retention members prior to being heat sealed or cut.

FIG. 8A is a perspective view of an optional folder that can be usedwith the manufacturing device of FIG. 6.

FIG. 9 is a schematic side elevational view of the resilient membersillustrated in FIG. 8.

FIG. 10 is a schematic illustration of a heat sealing and cutting deviceof the system of FIG. 6 which heat seals and cuts apart retentionmembers from the continuous strip of FIGS. 8 and 9.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

An improved packaging assembly is disclosed herein. The packagingassembly includes an improved structure which provides new alternativesto known suspension packaging systems.

In the following detailed description, terms of orientation such as“upper,” “lower,” “longitudinal,” “horizontal,” “vertical,” “lateral,”“midpoint,” and “end” are used herein to simply the description in thecontext of the illustrated embodiments. Because other orientations arepossible, however, the present inventions should not be limited to theillustrated orientations. Additionally, the term “suspension” is notintended to require that anything, such as an article to be packaged, issuspended above anything. Rather, the terms “suspended” as used herein,is only intended to reflect that such an article is held in a positionspaced from another member, such as at least one of the walls of acontainer or box. Those skilled in the art will appreciate that otherorientations of various components described herein are possible.

The suspension packaging assemblies disclosed herein can include a framemember 100 (FIG. 1) and a retention member 200 (FIG. 2). The suspensionpackaging assemblies and components disclosed herein are described inthe context of a suspension packaging assembly formed from a framemember and a retention member, because they have particular utility inthis context. However, the inventions disclosed herein can be used inother context as well.

With reference to FIG. 1, the frame member 100 is illustrated in anunfolded state and is constructed in accordance with an embodiment.Generally, the frame member 100 includes a central portion 110 and apair of opposing foldable portions 112, 114. The central member 110 canbe configured to engage or provide support for one or more articles tobe packaged.

In some embodiments, the foldable portions 112, 114 are configured toincrease a tension in the retention member 200 (FIG. 2) for holding oneor more articles in a desired position relative to the central portion110; an exemplary position being shown in FIGS. 4 and 5.

With continued reference to FIG. 1, the frame member 100 can beconstructed from various materials, including but without limitation,pulp, paper, cardboard, corrugated cardboard, plastic, combinationsthereof, and other appropriate materials. The chosen material forconstructing the packaging member 100 can be any substantially rigid,but foldable material. It will be appreciated that, although denominatedas rigid or substantially rigid, the chosen material would preferablyhave an amount of flexibility in the cases of physical impact. In someembodiments, the material used to form the packaging member 100 is asingle wall corrugated C-flute cardboard. The illustrated packagingmember 100 is a generally thin, planar member; however, the packagingmember 100 can have other configurations.

The central portion 110 can be sized and dimensioned so as to engage orprovide support for one or more articles. Although the central portion110 is described primarily as being disposed at the center of thepackaging member 100, the central portion 110 can be at other locations.Additionally, the central portion 110 can comprise a plurality ofmembers, each configured to engage an article. For the sake ofconvenience, the central portion 110 is described as a generally planarcentrally disposed member.

The size of the central portion 110, which defines a loading area, canbe chosen arbitrarily or to accommodate, support, or engage an articleof a particular size. The loading area size can be chosen based on thenumber and configuration of the articles on or proximate to the centralportion 110. In some non-limiting exemplary embodiments, the centralportion can be used to package one or more communication devices (e.g.,portable phones, cellular phones, radios, headsets, microphones, etc.),electric devices and components, accessories (e.g., cellular phonecovers), storage devices (e.g., disk drives), and the like. In certainembodiments, the central portion 110 is configured to package one moreportable music players, such as IPODs® or MP3 players.

It is contemplated that the central portion 110 can be designed topackage any number and type of articles. In the illustrated embodiment,the central portion 110 is somewhat square shaped and has a surface area(i.e., the loading area) of about 40-60 inches square. In somenon-limiting embodiments, the central portion has a loading area morethan about 40 inches square, 45 inches square, 50 inches square, 55inches square, 60 inches square, and ranges encompassing such areas.However, these are merely exemplary embodiments, and the central portion110 can have other dimensions for use in communication devices,packaging modems, hard drives, portable phones, or any other articlethat is to be packaged.

The illustrated central portion 110 has a generally flat upper surfacethat an article can rest against. Other non-limiting central portionscan have mounting structures, apertures, recesses, partitions,separators, or other suitable structures for inhibiting movement of anarticle engaging the central portion or for providing additional shockprotection. For example, the central portion 110 can have at least oneholder that is sized and configured to receive an article.

Fold lines 116, 118 can be defined between the central portion 110 andthe foldable portions 112, 114, respectively. The fold lines 116, 118can be formed as perforations in the frame member 100, i.e., broken cutlines passing partially or completely through the material forming theframe member 100. In the alternative, or in addition, the fold lines116, 118 can be crushed portions of the material forming the framemember 100. Of course, depending on the material used to construct theframe member 100, the fold lines 116, 118 can be formed as mechanicalhinges, thinned portions, adhesive tape, or any other appropriatemechanical connection which would allow various portions of the foldablemember to be folded or rotated with respect to each other. Theseconcepts apply to all the fold lines 116, 118 described herein, althoughthis description will not be repeated with respect to the other foldlines described below.

With such fold lines 116, 118, the foldable portions 112, 114 can bebent upwardly or downwardly relative to the central portion 110 asdesired. With this flexibility, the foldable portions 112, 114 can befolded upwardly so as to engage pockets on the retention member 200 andfolded downwardly to increase tension in the retention member 200,described in greater detail below.

The illustrated configuration of the frame member 100 is merely oneexample of many different kinds and shapes of frame members that can beused. U.S. Pat. Nos. 6,675,973, 7,882,956, 7,296,681, 7,753,209,8,028,838, and U.S. patent application Ser. Nos. 11/633,712, 12/497,474,12/958,261, and 13/221,784, the contents of each of which is herebyincorporated by reference, all disclose various different kinds of framemembers with various different combinations of additional foldingportions which can be used as a substitute for the illustrated framemember 100.

With reference to FIG. 2, the retention member 200 can be formed fromone or more resilient materials, then can optionally include a closuredevice 202. The retention member 200 is configured to engage andcooperate with the frame member 100. Optionally, the retention member200 can be configured to engage the foldable portions 112, 114 of theframe member 100 so as to, among other options, generate tension in theretention member 200 when the foldable portions 112, 114 are foldedrelative to the central portion 110.

The retention member 200 can be formed from a resilient body 204. Forpurposes of convenience for the following description, the body 204 isidentified as having a midpoint M position in the vicinity of the middleof the resilient body 204. Resilient body 204 can also include pocketportions 206, 208 disposed at opposite longitudinal and thereof. In theillustrated embodiment, the retention member 200 is formed from twopieces of resilient material connected together, and sized to cooperatewith the foldable portions 112, 114 of the frame member 100.

In the illustrated embodiment, the pockets 206, 208 are formed of foldsof the resilient body 204. The folds 206, 208, in some embodiments, canbe formed from heat sealing the material forming the resilient body 204while in a folded state, so as to form pockets. As illustrated in FIG.2, heat sealing lines 210, 212 extend along lateral edges of theresilient body 204 and act to secure two layers of material to eachother as well as form the pockets 206, 208.

One of ordinary skill in the art will appreciate that there are numerousmethods for forming the pockets 206, 208 in a resilient sheet materialsuch as the resilient member 204. However, it has been found that heatsealing is particularly advantageous as it does not require expensiveadhesives and the time consuming steps required for using suchadhesives. However, such adhesives can be used if desired. Weldingprocesses (e.g. induction welding), fusing techniques, and the like canalso be used to form the heat sealing lines 210, 212.

The retention member 200, in some embodiments, has a Length L₁ that issized depending in the devices with which the retention member 200 is tocooperate, such as goods. Thus, the Length L₁ can be sized such thatwhen the retention member 200 is in its final state, e.g., engaged withthe foldable portions 112, 114, it generates the desired tension for thecorresponding packaging application. Thus, the Length L₁ will be smallerwhere a higher tension is desired and will be larger where a lowertension is desired. Additionally, the Length L₁ might be different fordifferent sized articles that are to be packaged. One of ordinary skillin the art can determine the Length L₁ for the correspondingapplication. Additionally, one of ordinary skill in the art is fullyaware of how to perform industry standard drop tests to confirm theappropriate dimensioning of the frame member 100 and the retentionmember 200.

The retention member 200 can be formed of any resilient material. Insome embodiments, the retention member 200 can be formed of two layersof polyethylene films, low density polyethylene (LDPE), polyurethane,TPU, or virtually any polymer, or plastic film. The density of thelayers of film can be varied to provide the desired retentioncharacteristics such as overall strength, resiliency, and vibrationalresponse. Preferably the density of the material used to form theretention member 200 is determined such that the retention member 200 issubstantially resilient when used to package a desired article. Each ofthe layers used to form retention member 200 can be monolayer ormultilayer sheet depending on the application.

With reference to FIG. 3, in some embodiments, the retention member 200can form two pockets on each of the longitudinal ends.

For example, in some embodiments, as illustrated in FIG. 3, theretention member 200 can be formed from an upper layer of resilientmaterial 230 and a lower layer of resilient material 232. The layers230, 232 can be attached to each other along the heat sealing lines 210,212 so as to form a void there between. Additionally, the longitudinalends of these layers 230, 232 can be folded over at the longitudinalends, and then heat sealed in the folded position, to form the pocketportions 206, 208. In some embodiments, the heat sealing lines 210, 212extend along the lateral edges of the pockets 206, 208. As such, firstpockets 208A, 206A can be formed in the space between the two layers230, 232. Additionally, a second pocket can be formed 208B between thefolded portion and the upper portion of the retention member 200.Similarly, first and second pockets 206A, 206B, can also be formed inthe pocket portion 206.

These pockets 206, 206A, 206B, 208, 208A, 208B can be used to engage thefoldable portions 112, 114, described in greater detail below.

For example, as illustrated in FIG. 4, the frame member 100 can be usedin conjunction with the resilient member 200. The pocket portions 206,206A, 206B, 208, 208A, 208B can be moved over the foldable portions 112,114, as illustrated in FIG. 4, when the foldable portions 112, 114 arebend upwardly toward the upper surface of the central portion 110. Inthe illustrated embodiment, the foldable portions 112, 114 are insertedinto the pockets 206B, 208B. The length between the outer edges (i.e.,the length of the packaging of the frame member 100) of the foldableportions 112, 114 can be slightly greater than the length L₁ of theretention member 200. The article to be packaged 300 can be insertedbetween the resilient member 200 and the frame member 100 or between theupper and lower layers 230, 232 of the resilient member 200.

For example, in some embodiments, the retention member 200 can includethe opening device 202 which can be configured to allow the article 300to be inserted into the space between the upper and lower layers 230,232. In some embodiments, the opening device 202 can be in the form ofperforations in the upper layer 230 configured to allow the upper layer230 to be ruptured and opened thereby allowing the insertion of thearticle 300 into the space between the upper and lower layers 230, 232.

In other embodiments, the opening device 202 can be in the form of azipper, a tongue-and-groove zip-type closure member, Velcro®, lowstrength adhesives, flaps, magnets, or any other type of closing device.

Optionally, the opening device 202 can be positioned on the lower layer232 (illustrated in phantom line in FIG. 4). This configuration canprovide further advantages. For example, with the opening device 202positioned on the lower layer, 232, the opening device 202 is juxtaposedto and faces toward the central portion 110 of the frame member 100. Assuch, it is less likely that the article 300 can inadvertently passthrough the opening device 202 and exit the space between the layers230, 232.

In some embodiments, opening devices 202 can be provided on both of theupper and lower layers 230, 232. As such, the retention member 200 canbe used in various ways, allowing the article to be inserted into thespace between the layers 230, 232 through either of the opening deviceson either layer 230, 232.

With continued reference to FIGS. 4 and 5, with the article 300 disposedin either the space between the upper and lower layers 230, 232 orbetween the lower layer 232 and the upper surface of the central portion110, and with the foldable portions 112, 114, engaged with the pockets206, 208, the foldable portions 112, 114 can be rotated downwardly inthe direction of arrows R₁. In this initial movement from the positionillustrated in FIG. 4, the foldable portions 112, 114 move away from theMidpoint M of the retention member 200, thereby creating tension in theretention member 200.

As the foldable portions 112, 114 are further pivoted downwardly aboutthe fold lines 116, 118, until they are doubled back adjacent to thelower surface of the central portion 110, the foldable portions 112,114, continue to add additional tension into the resilient member 200,and more particularly, the upper and lower layers 230, 232 of theresilient member 200. The frame member 100 and the resilient member 200can be configured to form a spring when disposed in a box or container310 in the arrangement shown in FIG. 5. For example, the frame member100 itself can have some shape memory such that the fold lines 116, 118provide some resistance to movement. Additionally, as noted above, theLength L₁ of the retention member 200 can provide tension, resisting thefurther bending movement of the foldable portions 112, 114 about thefold lines 116, 118, respectively.

Accordingly, when the frame member 100, retention member 200, and thearticle 300 are arranged in the configuration shown in FIG. 5 inside thecontainer 310, reaction Forces F. resist downward movement of thearticle 300, thereby providing additional cushioning for the article300.

Further, the container 310 can define a maximum inner height, forexample, when the lid portion of the container 310 is closed. With themaximum inner height set to a dimension less than the maximum overallheight of the article 300 and frame member 100, the foldable portions112, 114 are maintained such that the angular position y (FIG. 5) ismaintained at an angle more acute that 90 degrees. Thus, the foldableportions are maintained in an orientation in which the frame member 100and resilient member 200 work together to act as a shock absorbingspring for the article 300.

FIGS. 6 through 9 illustrate an optional system for manufacturing theresilient member 200. The manufacturing system illustrated in FIG. 6 canbe made from well known plastic film processing equipment, such as thosecomponents in systems available from the Hudson-Sharp Machine Company.The various rollers, folders, cutters, guides, perforators, and heatsealing devices are all well known and commercially available. Those ofthe ordinary skill in the art understand how to arrange the variouscomponents described below in order to achieve the function and resultsdescribed below.

With continued reference to FIG. 6, the manufacturing system 400 caninclude a source portion 420, an opening device portion 450, a foldingportion 480, a drive portion 500, a heat sealing portion 520, and acutting portion 550.

The source portion 420 of the system 400 can include one or more sourcerolls of raw material for making the resilient member 200. In theillustrated embodiment, the source portion 420 can comprise, in someembodiments, one or more rolls of raw material for forming the resilientmember.

In the illustrated embodiment, a first roll 422 serves as a source ofthe upper layer of film for forming the upper layer 230 of the resilientmember 200 and the second roll 424 serves as a source for the materialperforming the second lower layer 232 of the resilient member 200. Inthe illustrated embodiment, the rolls 422, 424 are approximately thesame width.

Additionally, as described above, the material on the rolls 422, 424 canbe different kinds of materials, different thicknesses and havedifferent melting indexes. Additionally, as well known in the art, therolls 422, 424 are mounted so as to provide some resistance againstturning, so as to thereby maintain an acceptable minimum tension.

Those of ordinary skill in the art are familiar with the use of the term“melt index.” In particular, the “melt index” is a number that isassigned to a poly film and helps to organize the various types of polyinto general groupings based upon the melting temp of the resin they aremade out of. The softer the material, then usually the lower the meltindex will be assigned to that material.

As illustrated in FIG. 6, a strip of film 426, during operation, willunroll from the roll 422 and be pulled into the apparatus 400 forprocessing, as described below. Similarly, a strip of material 428,during operation, unrolls from the roll 424. The material 426 is usedfor forming the upper layer 230 of the resilient member 200 and thesecond strip 428 is used for forming the lower layer 232 of theresilient member 200. In some embodiments, the strips 426, 428 can havea melt index below 9.

The source 420 can also include one or more tensioning rollers 430configured for maintaining tension in the strips 426, 428 as they arepulled through the apparatus 400. The tensioning of such layers ofmaterial is well known to those of ordinary skill in the art, and thusis not described in further detail.

Optionally, as noted above, the manufacturing apparatus 400 can includean opening portion 450 configured to provide the opening device 202 tothe resilient member 200. In the illustrated embodiment, the openingdevice portion 450 is configured to perforate the strip of material 426so as to form an opening device 202 in the resilient member 200. In someembodiments, the opening portion 450 can include a block member 452 anda cutting head 454. In such an arrangement, the cutting head 454 caninclude a cutting blade (not shown) configured to reciprocate in adirection perpendicular to the material 426 in a timed fashion so as tocreate perforations at desired locations.

For example, as shown in FIG. 7, the cutting device 454 reciprocatesupward and downwardly to create a series of perforations 456 at spacedlocations along the material 426. The block 452 can provide support forthe material 426 as the cutting device 454 perforates the material 426.In some embodiments, both strips can be routed through the cuttingdevice 454, so as to provide opening device 202 in both layers 426, 428.

Optionally, the system 400 can include a set of diverter rollers 455,configured to allow the lower strip 428 to bypass the opening portion450. Thus, the opening portion can selectively provide opening devices202 to only one or to both of the strips 426, 428.

In some embodiments, one of or both of the strip 426, 428 can includeprinted portions 429, such as advertising, tradenames, trademarks,logos, coupons, or other indicia. Thus, the resulting retention member200 can include such printing on one or both of the layers 426, 428. Insome embodiments, one or both of the layers 426, 428 can be pre-printedwith the desired printed portions 429. For example, in some embodiments,the printed portions 429 can be applied to the layer 428 and the layer426 can be translucent or transparent. Thus, during use, the printedportions 429 can be viewed through the upper layer 426 (layer 230 inFIG. 4).

With continued reference to FIG. 6, the system 400 can approximatelyinclude a registration device 460 configured to provide a registrationfunction for the timing of actuation of the opening device 450, the heatcutting portion 550 (described below) or any other device that may beused to selectively alter the strips 426, 428 at desired locations. Forexample, one or more of the strips 426, 428 can be provided with one ormore detectable registration marks, such as visible lines (e.g., blackmarker), which can be used as a registration mark by the registrationdevice 460. The registration device 460 can include an optical sensor(not shown) configured to detect such a registration mark, and to outputa signal that can be used to control the various parts of the system 400to trigger actuation at the desired timing so as to produce the desiredeffects to the strips 426, 428 at the desired location. Suchregistration devices 460 are well known in the art and thus are notdescribed in greater detail below.

Using such as registration device 460, the system 400 can be configuredto create opening devices and heat seals in locations that are atpredetermined spacings from the printed portions 429. For example, theopening devices 202 can be centered on the printed portions 429 and thecuts created by the cutting portion 550 (described below) can bedisposed between the printed portions 429. Other spaced relationshipscan also be used.

As noted above, the manufacturing apparatus 400 can also include afolding portion 480. In the illustrated embodiment, the folding portion480 can include a first folding portion 482 and a second folding portion484. The folding portions 482, 484 can be made from curved pieces ofmetal, configured to guide the edges of the 426, 428 so as to fold overtoward the middle of those strips 426, 428.

With reference to FIG. 8, the folding portions 482, 484, can beconfigured to fold one of the lateral edges of the strips 426, 428 asthe pass through these folders 482, 484. For example, the foldingportion 482 can be configured to fold over the left lateral edge 486 ofthe strips 426, 428. Additionally the folder portion 484 can beconfigured to fold over the right side of lateral edge 488 of the strips426, 428. Further, the folders 482, 484 can be oriented such theresulting position of the opening device 202 is disposed on the top oron the bottom of the resulting retention member 200.

FIG. 9 illustrates a sectional view illustrating the unfolded stated ofthe layers 426, 428, and the orientation prior to reaching the folderportion 482 and a second folded state of the strips 426, 428 after beingdischarged from the second folding portion 484. FIG. 8A illustrates anexample of a single stage folding portion 482 that can be used toperform the folding noted above. This embodiment of a folder includes ablock member with two slits 483 skewed relative to the direction oftravel of the strips 426, 428. As the strips 426, 428 pass through theslits 483, the edges of the strips 426, 428 are folded inwardly, therebychanging the orientation of the strips 428, 428 to the orientation shownin FIG. 9.

With continued reference to FIG. 6, the drive portion 500 of themanufacturing apparatus 400 can include a plurality of rollers, one ormore of which can be driven with a motor so as to provide a substantialportion of the force for pulling the strips 426, 428 through the variousportions of the manufacturing apparatus 400. The configuration of such aset of drive rollers is well known in the art and is not described ingreater detail below. However, generally, the control of the speed ofthe drive rollers 500 is synchronized and otherwise controlled to be ina timed relationship with the operation of the tension portion 430,opening portion 450, folding portion 480, heat sealing portion 520,registration device 460, and cutting portion 550 with a programmablelogic controller, a dedicated processor, a general purpose computer, ahardwired controller, or the like.

In the illustrated embodiment, the heat sealing portion 520 and thecutting portion 550 are integrated into single component referred toherein as the heat sealing device 552. However, other configurations canalso be used. In the illustrated embodiment, the heat sealing device 552is configured to form two heat seals between the layers of the strips426, 428 and to also cut the strips 426, 428, between the two parallelheat seals. Individual resilient members 200 are then discharged fromthe device 552.

FIG. 10 illustrates a more detailed view of the heat sealing device 552.

With reference to FIG. 10, the heat sealing device 552 can include aheat sealing and cutting head 554 mounted so as to reciprocate relativeto the incoming strips 426, 428. As with the opening portion 450, theheat sealing and cutting head 554 is timed relative to the movement ofthe strips 426, 428 so as to provide the final product with the desiredshape.

The heat sealing and cutting head 554 can include a first heat sealingportion 556, a second heat sealing portion 558 and a cutting portion560. As the strips 426, 428 move under the head 554, the head can movedownwardly and press the first and second heat sealing portions 556, 558and the cutting portion 560 down into the strips 426, 428, so as tosimultaneously generate two heat sealed edges and cut those the strips426, 428 into individual retention members 200.

As noted above, the strips 426, 428 enter the heat sealing portion 552with both lateral edges folded, as shown in the lower portion of FIG.10. As such, the heat sealing portion 552 can receive the strips 426,428 which are generally not attached to each other as they enter theheat sealing portion 552, and simultaneously heat seal and cut thelateral edges, thereby forming individual resilient members 200 in asubstantially continuous manner. The heat sealing portion 552 caninclude a conveyor system to carry the sheets 426, 428 into the areabeneath the reciprocating head 554 and to carry the cut resilientmembers 200 away from the cutting head 554.

Optionally, the cutting portion 560 can be configured to only perforateor score the strips 426, 428 between the heat seals created by the heatsealing portions 558, 556 so that the resilient members 200 are stillattached but easily separatable from each other. This allows theresilient members 200 to be formed into a finished roll and torn off,similar to a roll of paper towels. Using this optional approach, theheat sealed strips 426, 428 can be rolled onto another roller (notshown) and shipped to customers as a roll of resilient members.

As noted above, the strips 426, 428 can be made from materials havingdifferent melt indexes. The melt index of a material refers to thetemperature at which the material will begin to flow and thereby canform clean heat seals. Most materials have different melt index values.The melt index values of many soft polys vary from about 7.0 to 9.7.Thus, the layer strips 426, 428 can have different melt indexes andconveniently if those melt indexes are in the range of about 7.0 toabout 10.0, they can be easily heat sealed together using theabove-described apparatus 400 and provide clean heat seals.

Further, the strips 426, 428 can have different modules of elasticity.In some embodiments, for example, more flexible material can be used asthe top layer 426 while a relatively stiffer layer can be used as thelower layer 428. For example, the upper layer, and some embodiments is apolyurethane while a low density polyethylene is used as the lower layer428. In this example, a six inch wide, 24 inch long strip of low densitypolyethylene will stretch only about six inches before failure while asix inch wide by 24 inch long strip of polyurethane will stretch 18inches before failure. Although these materials behave very differentlywith regard to failure, they can be easily heat sealed together usingthe apparatus 400 described above and provide the desired shockabsorption for packaging articles 300 described above.

The thicknesses of the strips 426, 428 can also be different. Forexample, depending on the application, one of the strips 426, 428 can bethinner than the other layer for example, by one or more mills(thousandths of an inch). This can help save cost of materials becausethinner materials are less expensive, less waste, etc.

Further, because various different kinds of material can be heat sealedtogether as described above, the colors of the materials can also bedifferent. For example, the strip 426 could be translucent ortransparent and the strip 428 could be translucent or opaque. Thus, thestrip 428 could include printed portions 429 that can be seen throughthe layer formed by the strip 426. The printed portions could be anyform of advertising, including but without limitation, trademarks,tradenames, service marks, logos, coupons, etc.

While at least one exemplary embodiment has been presented in theforegoing detailed description, it should be appreciated that a vastnumber of variations exist. It should also be appreciated that theexemplary embodiment or embodiments described herein are not intended tolimit the scope, applicability, or configuration of the claimed subjectmatter in any way. Rather, the foregoing detailed description willprovide those skilled in the art with a convenient road map forimplementing the described embodiment or embodiments. It should beunderstood that various changes can be made in the function andarrangement of elements without departing from the scope defined by theclaims, which includes known equivalents and foreseeable equivalents atthe time of filing this patent application.

What is claimed is:
 1. A suspension packaging assembly comprising: atleast one frame member having a central portion, a first end and asecond end disposed opposite the first end relative to the centralportion, a first foldable portion disposed at a first end of the and asecond foldable portion disposed at the second end; a resilientretention member assembly comprising a first layer having first andsecond longitudinal ends and first and second lateral edges, and asecond layer having first and second longitudinal ends and first andsecond lateral edges, the first layer being heat sealed to the secondlayer along the corresponding first and second lateral edges
 2. Thesuspension packaging assembly according to claim 1, wherein a firstlayer having a first thickness and a first elasticity and a second layerhaving a second thickness and a second elasticity.
 3. The suspensionpackaging assembly according to claim 1, wherein the first layer isformed of a first material, the second layer being formed of a secondmaterial that is different from the first material.
 4. The suspensionpackaging assembly according to claim 1, wherein the first layer isformed of a material having a first modulus of elasticity, the secondlayer being formed of a material that has a second modulus of elasticitythat is different from the first modulus of elasticity.
 5. Thesuspension package assembly according to claim 1, wherein the firstlayer is translucent and the second layer is opaque.
 6. The suspensionpackage assembly according to By 1, wherein the first layer is thinnerthan the second layer by at least one mil.
 7. The suspension packageassembly according to claim 6, wherein the first layer is thinner thanthe second layer by at least three mils.
 8. The suspension packageassembly according to claim 1, wherein the first layer is made fromlow-density polyethylene (LDPE) and the second layer is polyurethane. 9.A resilient retention member for providing damage protection forpackaged goods, comprising: a first layer having first and secondlongitudinal ends and first and second lateral edges; a second layerhaving first and second longitudinal ends and first and second lateraledges, the first layer being heat sealed to the second layer along thecorresponding first and second lateral edges.
 10. The retention memberaccording to claim 9 additionally comprising at least one opening in thefirst layer.
 11. The retention member according to claim 9, wherein thefirst layer is thinner than the second layer by at least one mil. 12.The retention member according to claim 9, wherein the first layer isthinner than the second layer by at least three mils.
 13. The retentionmember according to claim 9, wherein the first layer is heat sealed tothe second layer at two positions spaced inwardly from the first andsecond longitudinal ends of the first and second layers, respectively.